A practical guide to: Manufacturing rollouts that stick

Rollouts tend to fail somewhere between “the system is now running” and “the system is actually integral to our work.” McKinsey’s Global Lighthouse Network research estimates that as many as 70 percent of manufacturers end up in that gap, stuck just past the pilot stage with a digital initiative that never scales.

This guide covers the behaviors and habits that decide whether a rollout sticks: the five questions to answer before go-live, a maturity ladder to see where you stand, the meeting rhythm that keeps data in daily use, and what to do when leadership attention starts to fade. It includes a 90-day plan you can run on one line, plus templates you can use from day one.

‍

What’s inside:

• Why the first 90 days decide everything
• The difference between a pilot and a rollout that survives a normal week
• A five-stage maturity ladder to see where you are and what to do next
• Five questions to answer before go-live
• Three ways adoption stalls on the shop floor, and how to spot them early
• How to keep the habit alive after the novelty wears off
• What changes when you scale past one site
• A 90-day rollout plan with templates, checklists, and a weekly review agenda